Adhesive articles with improved air egress

ABSTRACT

Methods of making adhesive articles providing air egress by supplying a route for the air to flow out from under the construction are described. One method includes providing a release liner comprising a moldable layer having a release surface and a back surface; applying a first pattern of a first non-adhesive material to a first portion of the release surface; applying a second pattern of a second non-adhesive material to a second portion of the release surface, wherein the second pattern partially overlaps the first pattern; embedding at least one of the first or second non-adhesive materials into the moldable layer, and transferring an adhesive layer having a front and back surface and end edges onto the release liner, wherein the front surface of the adhesive layer is adhered to the release surface of the release liner.

TECHNICAL FIELD OF THE INVENTION

This invention relates generally to adhesive articles having improvedproperties such as air egress, repositionability and slideability, andto methods of making the same. Such articles are useful in diverseadhesive applications such as, for example, tapes, labels, industrialgraphics applications, articles used for graphic images, such as thoseused on vehicles, specialty materials for signage, and decorative wallcoverings.

BACKGROUND OF THE INVENTION

Pressure sensitive adhesives have enjoyed great acceptance for theirconvenience of use. The pressure sensitive adhesive is often used fortapes and articles containing graphic images. The advantages of thepressure sensitive adhesives are their strong bonding and simplicity ofapplication. One drawback of these products is the initial tenacity ofthe pressure sensitive adhesive. The positioning of the product must beprecise because of the initial strong bond of the adhesive. A needexists to make such products using pressure sensitive adhesives whichare repositionable, i.e. the product may be removed after lightapplication of pressure without damaging the product or the substrate.Similarly, a need exists for the products to be able to slide.Slideability allows for correction of alignment of the product withoutthe need of completely removing the product and possibly damaging theadhesive article or substrate.

When the product is a graphic image and is applied over an area like awall or truck panel, there is the possibility of trapping air under theproduct and forming bubbles or wrinkles. In order to avoid suchproblems, the product should exhibit air egress, i.e. the product shouldprovide a route for air trapped under the product to be removed or toescape.

A need exists for products which have one or more of the desirableproperties of air egress, repositionability and slideability.

SUMMARY OF THE INVENTION

This invention relates to an adhesive article which provides at leastone of air egress, repositionability and slideability. Air egress isprovided by supplying at least one route, such as areas of no initialadhesion or channels in which there is no contact between the adhesivearticle and the substrate, for the air to flow out from under theconstruction. The repositionability and slideability are obtained fromthe presence of areas of no initial adhesion and/or protrusions ofnon-adhesive materials from the adhesive.

In one embodiment, the invention relates to an adhesive articleincluding (a) a release liner having a release surface, molding layerand a second surface; (b) a continuous layer of adhesive having a firstsurface, a second surface and end edges, wherein the first surface ofthe adhesive is adhered to the release surface of the release liner; (c)a first pattern of first non-adhesive material forms having a firstsurface and a second surface; and a second pattern of secondnon-adhesive material forms having a first surface and a second surface,wherein the second pattern partially overlaps the first pattern; atleast one of the first and second patterns is embedded into the releasesurface and molding layer of the release liner; the first surface ofeach of the two patterns is in contact with the adhesive layer; and thefirst surface of at least a portion of the first pattern of thenon-adhesive material forms is in a plane that is different from theplane of the first surface of at least a portion of the secondnon-adhesive material forms.

The invention further relates to methods of preparing the adhesivearticles. One method of making the adhesive articles of the presentinvention comprises (a) providing a release liner comprising a moldinglayer having a release surface and a second surface; (b) applying afirst pattern of a first non-adhesive material to a first portion of therelease surface; (c) applying a second pattern of a second non-adhesivematerial to a second portion of the release surface wherein the secondpattern partially overlaps the first pattern; (d) embedding at least oneof the first or second non-adhesive materials into the molding layer;and (e) applying an adhesive layer having a first surface, a secondsurface, and end edges onto the release liner, wherein the first surfaceof the adhesive layer is adhered to the release surface of the releaseliner.

In yet another embodiment, the present invention relates to an adhesivearticle, comprising a release liner comprising a release surface, amolding layer and a second surface; a continuous layer of adhesivehaving a first surface, a second surface and end edges, wherein thefirst surface of the adhesive is adhered to the release surface of therelease liner; a first embossed pattern in the release surface and themolding layer of the release liner; and second pattern of a non-adhesivematerial forms, wherein the second pattern partially overlaps the firstembossed pattern and a portion of the second pattern at least partiallyfills in portions of the first embossed pattern, said embossed patternand the non-adhesive material forms each having an exposed first surfaceand a second surface, wherein the exposed first surface of at least aportion of the embossed pattern is in a plane that is different from theplane of the exposed first surface of at least a portion of the secondpattern of non-adhesive materials forms.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view depicting a release liner to which a firstpattern of a non-adhesive material has been applied, in accordance withthe present invention.

FIG. 2 is a perspective view, and FIG. 2′ is a cross-sectional view,both depicting the release liner of FIG. 1 following a step of embeddingthe non-adhesive material, in accordance with an embodiment of thepresent invention.

FIGS. 3, 3′, 3″ and 4-7 are perspective and cross sectional viewsdepicting steps of a first embodiment of making an adhesive articleincluding a release liner with a first pattern and a second pattern of anon-adhesive material on the release surface.

FIGS. 8, 9, 9′, 9″, 9′″, 10 and 11 are perspective and cross sectionalviews depicting steps of a second embodiment of making an adhesivearticle including a release liner with a first pattern and a secondpattern of a non-adhesive material on the release surface.

FIGS. 12 a, 12 b, 13, 14, 14′, 14″, 15 and 16 are perspective and crosssectional views depicting steps of a third embodiment of making anadhesive article including a release liner with a first embossed patternand a second pattern of a non-adhesive material on the release surface.

FIG. 17 is a schematic cross-sectional view depicting a method ofembedding a non-adhesive material into a release liner, in accordancewith an embodiment of the present invention.

FIG. 18 is a schematic cross-sectional view depicting two embodiments ofa textured surface of a roller used, for example, in embedding anon-adhesive material into a release liner, or for applying a texture toa release liner, in accordance with an embodiment of the presentinvention.

It should be appreciated that for simplicity and clarity ofillustration, elements shown in the Figures have not necessarily beendrawn to scale. For example, the dimensions of some of the elements maybe exaggerated relative to each other for clarity. Further, whereconsidered appropriate, reference numerals have been repeated among theFigures to indicate corresponding elements.

DETAILED DESCRIPTION

It should be appreciated that the process steps and structures describedbelow do not form a complete process flow for manufacturing a completeadhesive article. The present invention can be practiced in conjunctionwith techniques currently used in the art, and only so much of thecommonly practiced process steps are included as are necessary for anunderstanding of the present invention.

As used herein, the term “textured”, when used in reference to a surfacefeature, means that the surface has a regular or repeating textureapplied to the surface. As used herein, the term “matte”, when used inreference to a surface feature, means that the surface has a random,roughened surface. These terms are defined to include surface elementswhich are formed as a result of processes applied to the surface beyond,or in addition to, the processes used to form the surface. In otherwords, the texture or the matte condition can be applied in a stepseparate from the step of forming the surface per se.

In one embodiment, the adhesive articles of the invention comprise

a release liner comprising a release surface, a molding layer and asecond surface;

a continuous layer of adhesive having a first surface, a second surfaceand end edges, wherein the first surface of the adhesive is adhered tothe release surface of the release liner;

a first pattern of first non-adhesive material forms having a firstsurface and a second surface; and

a second pattern of second non-adhesive material forms having a firstsurface and a second surface, wherein the second pattern partiallyoverlaps the first pattern; at least one of the first and secondpatterns is at least partially embedded in the release surface andmolding layer of the release liner; the first surface of each of the twopatterns is in contact with the release surface of the release liner,the second surface of each of the two patterns is in contact with theadhesive layer; and the first surface of at least a portion of the firstpattern of non-adhesive material forms is in a plane that is differentfrom the plane of the first surface of at least a portion of the secondpattern of non-adhesive material forms.

In another embodiment, the adhesive articles of the invention comprise arelease liner comprising a release surface, a molding layer and a secondsurface; a continuous layer of adhesive having a first surface, a secondsurface and end edges, wherein the first surface of the adhesive isadhered to the release surface of the release liner; a first embossedpattern in the release surface and the molding layer, and a secondpattern of a non-adhesive material forms wherein the second patternpartially overlaps the embossed first pattern and a portion of thesecond pattern at least partially fills in portions of the firstembossed pattern, said embossed pattern and the non-adhesive materialforms having an exposed first surface and a second surface, wherein theexposed first surface at least a portion of the embossed pattern is in aplane that is different from the plane of the exposed first surface ofat least a portion of the non-adhesive material forms.

In another embodiment the adhesive articles do not contain a releaseliner. In one embodiment, such adhesive articles may be described ascomprising a continuous layer of adhesive having a first surface, asecond surface and end edges, and a first pattern of first non-adhesivematerial forms and a second pattern of second non-adhesive materialforms wherein the second pattern partially overlaps the first pattern;at least one of said first and second patterns is at least partiallyembedded in the first surface of the adhesive layer; each of said firstand second patterns has an exposed first surface and an opposite secondsurface that is in contact with the adhesive; the first surface of atleast a portion of the first pattern of non-adhesive forms is in a planethat is different from the plane of the first surface of at least aportion of the second pattern of non-adhesive forms; and at least aportion of the first pattern protrudes from the first surface of theadhesive layer.

In another embodiment, the adhesive article of the invention comprises acontinuous layer of adhesive having a first surface and a secondsurface, and a first embossed pattern in the first surface of theadhesive layer, and

a second pattern of non-adhesive material forms, wherein the secondpattern at least partially overlaps the first pattern and is embedded inthe first surface of the adhesive layer; each of said embossed patternand second pattern has an exposed first surface wherein the firstsurface of at least a portion of the first embossed pattern is in aplane that is different from the plane of the first surface of at leasta portion of the second pattern of non-adhesive forms.

One of the features of the present invention is that the first surfaceof at least a potion of the first pattern of non-adhesive material formspresent in the adhesive articles is in a plane that is different fromthe plane of the first surface of at least a portion of the secondpattern of non-adhesive material forms as will be discussed in moredetail below in relation to the figures.

Release liners useful in the adhesive articles and methods of presentinvention may be those known in the art which include a molding layerhaving a release surface and a second surface. A molding layer is alayer into which a non-adhesive material, such as those disclosedherein, may be imbedded by the methods disclosed herein and which areknown in the art. Thus, in one embodiment, the release liners useful inthe invention may comprise a layer of moldable material having at leastone surface that inherently has release properties. For example, a layerof low density polyethylene having release characteristics can be usedas the release liner in the adhesive articles and methods of theinvention.

Alternatively, when the molding layer does not inherently havesufficient release characteristics, one or more surfaces of the moldinglayer can be coated with a release composition. Release compositions areknown in the art and such compositions include a variety of siliconecompositions. In yet another embodiment, the release liners usefulherein comprise a substrate or base layer having a molding layer on oneside, and a release coating covering the molding layer. The moldinglayer may be a polyolefin such as polyethylene and polypropylene.Examples of such release liners include polyethylene coated papers witha commercial silicone release coating and polyethylene coatedpolyethylene terephthalate films with a commercial silicone releasecoating. In one embodiment, the release liner is kraft paper which has acoating of low density polyethylene on the front side with a siliconerelease coating on the polyethylene, and a coating of high densitypolyethylene on the back side. Other release liners known in the art arealso suitable as long as they contain a molding layer and are selectedfor their release characteristics relative to the adhesive chosen foruse in the present invention. In one embodiment of the invention, therelease liner has a molding layer of polymer under the release coating,which softens upon the application of heat, allowing the non-adhesivematerial to be embedded into the molding layer of the release liner.Embedding the non-adhesive material into the release liner maintains thethree-dimensional stability of the printed pattern and protects thepattern during handling, storage and transport of the adhesive article.

The release surface of the release liner may have a textured finish, amatte finish, a smooth finish, or a patterned finish. The release layermay have a randomly microstructured surface such as a matte finish, orhave a pattern of three-dimensional microstructures. The microstructuresmay have a cross-section which is made up of circles, ovals, diamonds,squares, rectangles, triangles, polygons, lines or irregular shapes,when the cross-section is taken parallel to the surface of the releasesurface. The release liner may also have randomly distributednon-adhesive particulate material applied to the surface of the releasesurface. The non-adhesive particulate is then embedded into the releaseliner along with the patterned non-adhesive material.

In one embodiment, the release liner useful in the adhesive articles andmethod of the invention has a release coating on both sides; and inanother embodiment, one side has a release coating of a higher releasevalue than the release coating of the other side.

The adhesive articles of the invention also comprise a continuousadhesive layer which may comprise a pressure sensitive adhesive and/or aheat activated adhesive. The adhesive layer typically has a thicknessfrom about 10 μm to about 125 μm, or from about 25 μm to about 75 μm, orfrom about 10 μm to about 50 μm. In one embodiment, the coat weight ofthe pressure sensitive adhesive is in the range of about 10 to about 50grams per square meter (gsm), and in one embodiment about 20 to about 35gsm.

In one embodiment, the first surface of the adhesive layer of thearticles has a Sheffield roughness of at least about 10 or at leastabout 75, or at least about 150. The adhesive layer may itself have theroughness or may be formed when the adhesive is coated onto a releaseliner. It is understood that the release liner may have a Sheffieldroughness at least about 10 or at least about 50, or at least about 75or at least about 150. The adhesive will replicate the complementarytexture or pattern of the release liner. Alternatively, the surface ofthe release liner can be rougher depending on the desired configurationof the adhesive article. The Sheffield roughness is determined by TAPPIT 538 om-88.

The pressure-sensitive adhesives can be any of the pressure sensitiveadhesives known in the art. These include rubber based adhesives,acrylic adhesives, vinyl ether adhesives, silicone adhesives, andmixtures of two or more thereof. Included are the pressure sensitiveadhesive materials described in “Adhesion and Bonding”, Encyclopedia ofPolymer Science and Engineering, Vol. 1, pages 476-546, IntersciencePublishers, 2nd Ed. 1985, the disclosure of which is hereby incorporatedby reference. The pressure sensitive adhesive materials that are usefulmay contain as a major constituent an adhesive polymer such as acrylictype polymers, block copolymers, natural, reclaimed or styrene butadienerubbers, tackified natural or synthetic rubbers, random copolymers ofethylene and vinyl acetate, ethylene-vinyl-acrylic terpolymers,polyisobutylene, poly(vinyl ether), etc. The pressure sensitive adhesivematerials are typically characterized by glass transition temperaturesin the range of about −70° C. to about 10° C.

Other materials may be included in the pressure sensitive adhesivematerials. These include solid tackifying resins, liquid tackifiers(often referred to as plasticizers), antioxidants, fillers, pigments,waxes, etc. The adhesive materials may contain a blend of solidtackifying resins and liquid tackifying resins (or liquid plasticizers).Particularly useful adhesives are described in U.S. Pat. Nos. 5,192,612and 5,346,766 which are incorporated herein by reference.

The layer of pressure sensitive adhesive can be applied using standardcoating techniques, such as transfer coating, curtain coating, gravurecoating, reverse gravure coating, offset gravure coating, rollercoating, brushing, knife-over roll coating, air knife coating meteringrod coating, reverse roll coating, doctor knife coating, dipping, diecoating, spraying, and the like. The application of these coatingtechniques is well known in the industry and can effectively beimplemented by one skilled in the art. The knowledge and expertise ofthe manufacturing facility applying the coating determine the preferredmethod. Further information on coating methods can be found in “ModernCoating and Drying Technology”, by Edward Cohen and Edgar Gutoff, VCHPublishers, Inc., 1992. Alternatively, an adhesive layer can be appliedby transfer of an adhesive layer on a release liner by procedures knownto those skilled in the art.

The non-adhesive materials of the at least two patterns may be the sameor different. In one embodiment, the non-adhesive material includesnon-adhesive polymers, including ink compositions, applied by printingmethods. In another embodiment, the non-adhesive material e.g., a metalor metallic or metal-containing material is applied by vacuummetallization or by sputtering. The non-adhesive material, after drying,cooling, and/or curing, releasably adheres to the release surface of therelease liner. In one embodiment, the non-adhesive composition used toform the patterns contains greater than 50%, or greater than 75%, orgreater than 85% solids. In another embodiment, the non-adhesivecomposition is 100% solids. Here and elsewhere in the specification andclaims, the limits of the ranges and ratios may be combined.

In one embodiment, the non-adhesive material can be any material thatcan be used as the ink on a printing machine, provided that upon drying,cooling, and/or curing, the non-adhesive material is not tacky. Thenon-adhesive material may be made of organic polymeric material such aspolyurethane, polyvinyl chloride, acrylic polymers, acetate,polyethylene, polypropylene or polystyrene and the like.

In one embodiment, the non-adhesive composition is a UV curable ink. Theultraviolet radiation curable inks useful in the invention generallycomprise a binder which comprises one or more photopolymerizablemonomers. The photopolymerizable monomers generally are ethylenicallyunsaturated compounds. The unsaturated compounds may contain one or moreolefinic double bonds, and they may be low molecular weight compounds,(monomeric) or high molecular weight compounds (oligomeric).Illustrative examples of monomers containing one double bond areacrylates such as alkyl(meth)acrylates or hydroxyalkyl(meth)acrylatessuch as methyl-, ethyl-, butyl-, 2-ethylhexyl- or2-hydroxyethylacrylate, isobornylacrylate, methyl- or ethylmethacrylate.Further examples of photopolymerizable monomers are acrylonitrile,acrylamide, methacrylamide, N-substituted (meth) acrylamides, vinylesters such as vinyl acetate, vinyl ethers such as isobutylvinyl ether,styrene, alkylstyrenes and halostyrenes, N-vinylpyrrolidone, vinylchloride or vinylidene chloride.

Monomers containing a plurality of double bonds are typically thediacrylates of ethylene glycol, 1,3-propylene glycol, 1,4-butanediol,1,4-cyclohexane diol, neopentyl glycol, hexamethylene glycol, orbisphenol A polyacrylates such as trimethylolpropane triacrylate andpentaerythritol triacrylate or tetraacrylate, vinyl acrylate, divinylbenzene, divinyl succinate, diallyl phthalate, triallylphosphate,triallylisocyanurate or tris(2-acryloyloxy)ethyl-isocyanurate.

Typical examples of high molecular weight (oligomeric) polyunsaturatedcompounds are acrylated epoxy resins, acrylated polyethers, acrylatedpolyurethanes or acrylated polyesters. Further examples of unsaturatedoligomers are unsaturated polyester resins which are normally preparedfrom maleic acid, phthalic acid and one or more diols and which havemolecular weights of about 500 to about 3000. Such unsaturated oligomersmay also be referred to as prepolymers. Single component systems basedon photocurable prepolymers are often used as binders for printing inks.Unsaturated polyester resins are normally used in two-component systemstogether with a monounsaturated monomer such as described above,preferably with styrene.

The unsaturated compounds also can be used in admixture withnon-photopolymerizable film-forming components. These components maytypically be drying polymers or their solutions in organic solvents,such as nitrocellulose. They may also, however, be chemically curable orthermocurable resins such as polyisocyanates, polyepoxides or melamineresins. The concomitant use of thermocurable resins is important for usein so-called hybrid systems which are photopolymerized in a first stepand crosslinked by a thermal after treatment in a second step.

The UV radiation curable inks also should contain at least onephotoinitiator. A wide range of different photoinitiators is at presentavailable for UV radiation curable systems. They include benzophenoneand benzophenone derivatives, benzoin ethers, benzil ketals,dialkoxyacetophenones, hydroxyacetophenones, aminoacetophenones,haloacetophenones or acryloxyphosphine oxides. They differ in that theyhave different absorption maxima. To cover a wide absorption range it ispossible to use a mixture of two or more photoinitiators. The totalamount of photoinitiator in the UV radiation curable compositions may bein the range of from about 0.05 to about 7, or 10% by weight of thetotal composition. Preferably the compositions contain from about 0.2%to about 5% by weight of the photoinitiator.

Amines may be added to accelerate the photopolymerization, for exampletriethanolamine, N-methyl-diethanolamine, p-dimethylaminobenzoate orMichler's ketone. The photopolymerization can further be accelerated bythe addition of photosensitizers which displace or broaden the spectralsensitivity. These photosensitizers are preferably aromatic carbonylcompounds such as thioxanthone, anthraquinone and 3-acyl-coumarinderivatives as well as 3-(aroylmethylene)-thiazolines.

Hindered amine light stabilizers (HALS) which function asco-stabilizers, also may be added to the UV radiation curable printingcompositions used in the present invention. Examples of hindered aminelight stabilizers include those listed and recited in U.S. Pat. Nos.5,112,890 and 4,636,408, which are incorporated herein by reference. Aspecific example of a hinder amine light stabilizer useful in theprinting inks is TINUVIN® 292 which is identified asbis(1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate.

In addition to the above described binder materials and photoinitiators,the UV radiation curable inks used in the present invention may alsocontain coloring matter selected from organic pigments, inorganicpigments, body pigments and dyes which are known and have been used inthis art. Examples of useful pigments include titanium dioxide, cadmiumyellow, cadmium red, cadmium maroon, black iron oxide, carbon black,chrome green, gold, silver, aluminum and copper. Examples of dyesinclude alizarine red, Prussian blue, auramin naphthol, malachite green,etc. Generally the concentration of the pigment or dye in the ink willbe from about 0 to about 70% by weight, and in one embodiment, fromabout 0.1% to about 50% by weight.

In addition to the above described coloring matter, the UV radiationcurable inks used in the present invention may also contain fillers,extenders, surfactants, and the like which are known and have been usedin this art. Examples of useful fillers and extenders include silicondioxide, fumed silica, glass or ceramic microspheres, and glassorceramic bubbles. Generally the concentration of the filler or extenderwill be from about 0 to about 70% by weight, and in one embodiment, fromabout 0.5% to about 50% by weight.

The printing inks may also contain at least one UV absorber whichprovides weathering protection and helps prevent microcracking. Theamount of UV absorber included in the UV radiation curable ink should bemaintained at a practical minimum since the presence of the UV absorbermay increase the curing rate. A variety of UV absorbers are known anduseful in the present invention and these include UV absorbers belongingto the group of photopolymerizable hydroxybenzophenones andphotopolymerizable benzotriazoles. U.S. Pat. No. 5,369,140 describes aclass of 2-hydroxyphenyl-s-triazines that are useful as UV absorbers forradiation curable systems. The triazines are effective for stabilizingcured films when exposed to sunlight over a long period of time, andthese stabilizers do not interfere with UV radiation curing of the inks.The triazine UV absorbers are effective in amounts of from about 0.1 toabout 2% by weight. The UV absorbers may be used in combination withother light stabilizers such as sterically hindered amines. Thedisclosure of the '140 patent is hereby incorporated by reference forits disclosure of such UV absorber combinations. U.S. Pat. Nos.5,559,163 and 5,162,390 also describe UV absorbers which are useful inthe inks of the present invention.

Examples of useful UV curable inks include those available from Decochemunder the trade designation Poly-Rad plastics, as well as UV curableinks commercially available from Acheson and Daw Chemical Company.

In one embodiment of the invention, the ink used to form thenon-adhesive patterns on the release liner is a coalescing ink. The inkdoes not efficiently wet out on the surface of the release liner, butcoalesces into smaller areas of ink with an increase in height. Thus,depending on the degree of coalescence, a line of printed ink can form anarrower line, or a line made up of what appear to be random small beadsof ink, or a combination, all with an increase in height. The narrowerline, small beads, or combination are then embedded into the releaseliner. The thickness of the ink applied to the surface of the releaseliner can also affect the degree of coalescence. Surfactants may beadded to the ink composition to control the degree of coalescence aswell.

In one embodiment of the invention, the ink used to form thenon-adhesive patterns comprises a porous non-adhesive. The porousnon-adhesive may have elastomeric properties, so that if it iscompressed, it essentially returns to its original shape. For examplethe porous non-adhesive comprises an ink containing a blowing agent thatcauses the ink to expand, forming an open or closed cell, or combinationthereof. The blowing agent is activated, for example, by the applicationof heat to the ink. Other examples of porous non-adhesives includesuspensions of gas and/or particles in a binder.

Substances which can be deposited by the sputtering or metallizationprocesses also can be used to form the non-adhesive patterns in theadhesive articles of the invention. Examples of such metals include:aluminum, silver, gold, chrome, copper and nickel.

As noted, in one embodiment, the adhesive articles of the presentinvention comprise a first pattern of a first non-adhesive materialforms and a second pattern of a second non-adhesive material forms. Thepresent invention may include additional patterns of non-adhesivematerial. The present invention may further include additionalnon-adhesive materials randomly distributed, i.e., in no regularpattern. The non-adhesive materials of the two or more patterns may bethe same or different. The patterns, independently, can be a pluralityof dots, lines or bars, continuous or broken, etc. provided onepartially overlaps the other pattern. In one embodiment, when lines areused, at least about 50% of the lines extend and intersect the end toedges of the adhesive layer to provide improved air egress. The linesmay vary in size provided that air egress is maintained. The lines andother patterns generally have an average thickness from about 0.3microns (μm) to about 100 μm, or from about 0.5 μm to about 50 μm, orfrom about 3 μm to about 30 μm. The width of the lines may also varywidely. An example of a useful range for line width is from about 12 μmto about 250 μm, or from about 25 μm to about 125 μm, or from about 50μm to about 75 μm. The pattern may be a grid of intersecting lines, aweave pattern, a waffle pattern, diagonal straight and curved lines,tiled geometric figures, such as hexagons, rectangles, overlappingcircles or triangles, or lines in a cross hatch pattern. In addition tothe patterns that may be used such as a grid of intersecting lines, dotsand other random shapes may be embedded in the molding layer of releaseliner to increase desirable properties such as air egress,repositionability and slideability.

In one embodiment, the non-adhesive material is an ink comprising a UVcurable polymer composition, such as a UV curable acrylic orpolyurethane composition. After application, the ink is cured byirradiation in a UV exposure apparatus as is well known to those skilledin the art of printing and UV curing. UV light sources such as lowpressure mercury lamps, high pressure mercury lamps, xenon lamps, arclamps and gallium lamps are useful. It is also possible, but notnecessary, to improve the curability of the ink by heating afterirradiation.

In one embodiment, the non-adhesive material is a polymer compositionwhich is able to be printed by any suitable printing technique such asscreen printing, roller coat printing, flexographic printing,lithographic printing, gravure printing, laser printing, ink jetprinting, brushing, spraying, dipping or coating. The type of printingmay be any type which can print on the release liner. One particularlyuseful printing method is a modification of flexographic printing whichprovides both the printing and embedding of the non-adhesive material.

The non-adhesive material may also be applied to the release liner bymeans of patterned vacuum metallization or sputtering. In thisembodiment, the non-adhesive layer typically has a thickness from about30 nanometers (nm) to about 3000 nm, from about 100 nm to about 2000 nm,or from about 300 nm to about 1500 nm.

As described above, the adhesive articles may optionally comprise afacestock. In one embodiment, a facestock may be applied to the secondsurface of the adhesive layer which has already been releasably adheredto a release liner. Alternatively, a combination of a facestock and anadhesive may be applied to the release liner. The facestock may be anyof those which are useful for decorative or graphic image applications.The facestocks typically have a thickness from about 10 μm to about 300μm, or from about 25 μm to about 125 μm. The facestocks include paper,polyolefins (linear or branched), polyamides, polystyrenes, nylon,polyesters, polyester copolymers, polyurethanes, polysulfones,polyvinylchloride, styrene-maleic anhydride copolymers,styrene-acrylonitrile copolymers, ionomers based on sodium or zinc saltsof ethylene methacrylic acid, polymethyl methacrylates, cellulosics,fluoroplastics, acrylic polymers and copolymers, polycarbonates,polyacrylonitriles, and ethylene-vinyl acetate copolymers. Included inthis group are acrylates such as ethylene methacrylic acid, ethylenemethyl acrylate, ethylene acrylic acid and ethylene ethyl acrylate.Also, included in this group are polymers and copolymers of olefinmonomers having, for example, 2 to about 12 carbon atoms, and in oneembodiment 2 to about 8 carbon atoms. These include the polymers ofalpha-olefins having from 2 to about 4 carbon atoms per molecule. Theseinclude polyethylene, polypropylene, poly-1-butene, etc. An example of acopolymer within the above definition is a copolymer of ethylene with1-butene having from about 1 to about 10 weight percent of the 1-butenecomonomer incorporated into the copolymer molecule. The polyethylenesthat are useful have various densities including low, medium and highdensity ranges. The low density range is from about 0.910 to about 0.925g/cm³; the medium density range is from about 0.925 to about 0.940g/cm³; and the high density range is from about 0.94 to about 0.965g/cm³. Films prepared from blends of copolymers or blends of copolymerswith homopolymers also are useful. The films may be extruded as amonolayer film or a multi-layered film.

In one embodiment, the facestock is a polymeric facestock, whichcontains migratory additives. The facestocks are preferablypolyvinylchloride facestocks. The additives include plasticizers andantioxidants. The plasticizer is a high-boiling solvent or softeningagent, usually liquid. It is an ester made from an anhydride or acid anda suitable alcohol that usually has between 6 to 13 carbon atoms. Theplasticizers may be adipate, phosphate, benzoate or phthalate esters,polyalkylene oxides, sulfonamides, etc. The plasticizers include but arenot limited to DOA plasticizer (dioctyl adipate), TEG-EH plasticizer(triethylene glycol di-2-ethylhexanoate), TOM plasticizer (trioctyltrimellitate), triacetin plasticizer (glyceryl triacetate), TRIB.plasticizer (2,2,4-trimethyl-1,3-pentanediol diisobutyrate), DEPplasticizer (diethyl phthalate), DOTP plasticizer (dioctylterephthalate), DMP plasticizer (dimethyl phthalate), DOP plasticizer(dioctyl phthalate), DBP plasticizer (dibutyl phthalate), polyethyleneoxide, toluenesulfonamide, dipropylene glycol benzoate, and the like.

In one embodiment, the adhesive articles of the invention may beprepared by

(a) providing a release liner comprising a molding layer having arelease surface and a second surface;

(b) applying a first pattern of a first non-adhesive material to a firstportion of the release surface;

(c) applying a second pattern of a second non-adhesive material to asecond portion of the release surface, wherein the second patternpartially overlaps the first pattern;

(d) embedding at least one of the first or second non-adhesive materialsinto the molding layer; and

(e) applying an adhesive layer having a first surface and a secondsurface onto the release liner, wherein the first surface of theadhesive layer is adhered to the exposed portions of the non-adhesivematerials and to the release surface of the release liner.

After the adhesive layer is applied, the release liner may be removed toprovide adhesive articles of other embodiments of the invention asdescribed herein.

In another embodiment, (hereinafter sometimes referred to as the “firstembodiment”), only the first pattern of non-adhesive material isembedded into the molding layer, i.e., the first pattern of non-adhesivematerials forms is embedded in the molding layer before the secondpattern of non-adhesive material forms is applied to the release liner.Thus, the process of the first embodiment comprises

(a) providing a release liner comprising a molding layer having arelease surface and a second surface;

(b) applying a first pattern of a first non-adhesive material to a firstportion of the release surface;

(c) embedding the first pattern of a first non-adhesive material intothe molding layer,

(d) applying a second pattern of a second non-adhesive material to asecond portion of the release surface wherein the second patternpartially overlaps the first pattern, and

(e) applying an adhesive layer having a first surface and a secondsurface onto the release liner, wherein the first surface of theadhesive layer is adhered to the exposed portions of the non-adhesivematerials and to the release surface of the release liner.

FIGS. 1, 2, 2′, 3, 3′, 3″ and 4-7 are perspective and cross sectionalviews depicting a process of a first embodiment of making an adhesivearticle of the invention. FIG. 1 is a perspective view of a releaseliner 100 containing a first pattern 106 having an upper or secondsurface 106 a and a lower or first surface 106 b which is in contactwith the release surface 102. The release liner 100 includes a releasesurface 102, molding layer 104 and substrate 101. A first pattern 106 ofa first non-adhesive material has been applied to the release surface102. In the embodiment shown in FIG. 1, the first pattern 106 has beenapplied in a direction substantially parallel with the sides of therelease liner, as represented by the arrow 108. It should be understoodthat the first pattern 106 in this and other embodiments describedherein and illustrated in the figures, may be applied at an angle, suchas about 22.5°, about 30°, about 45°, about 60°, about 75°, about 90° orabout any other selected angle relative to the direction defined by thearrow 108. Thus, overlapping patterns may form shapes such as squares ordiamonds when the release liner is viewed in a plan view. In combinationwith the angles relative to the direction indicated by arrow 108 atwhich the first pattern 106 is applied, both patterns may be applied atany selected angle with the exception of a parallel, exactly overlappingidentical pattern, in which case, the effect would be to deposit onlyone pattern. The release liner 100 may be any suitable release linerhaving a molding layer 104 into which a pattern of non-adhesivematerial, such as the pattern 106, may be embedded, as described below.

Following application of the first pattern 106, the first pattern 106 isembedded into the release surface 102 and molding layer 104 as shown inFIG. 2. Suitable methods for embedding are described below.

FIG. 2 is a perspective view of the release liner 100, after the firstpattern 106 of the first non-adhesive material has been embedded intothe release surface 102 and the molding layer 104. FIG. 2′ is across-sectional view taken at line 2′-2′ of FIG. 2. In the embodimentshown in FIGS. 2 and 2′, the first pattern 106 is embedded into themolding layer 104 to a level such that the second surface 106 a of thefirst pattern 106 (hereinafter generally referred to as the secondsurface 106 a of the first pattern 106) is substantially coplanar withthe upper surface of the release liner 100. That is the second surface106 a of the first pattern 106 is substantially coplanar with a plane102 a defined by the release surface 102 (see FIG. 2′). In otherembodiments (not shown), the first pattern 106 may be embedded to adepth whereby the second surface 106 a of the first pattern 106 iseither above or below the plane defined by the release surface 102. Inthese latter embodiments, the first pattern 106 either is only partiallyembedded, in which a portion of the first pattern 106 extends above theplane 102 a, or is over-embedded, in which the second surface of thefirst pattern 106 is below the plane 102 a.

FIGS. 3, 3′ and 3″ depict the release liner 100 after a second pattern110 of a second non-adhesive material is applied onto the releasesurface 102 of the release liner 100 and at least a portion of thesecond pattern 110 overlaps the first pattern 106. One surface of thepattern 110 (first surface) identified as 110 b, is in contact with therelease surface 102 and the first surface 106 a of the first pattern106, and the opposite surface (second surface) 110 a of pattern 110 isexposed. FIG. 3′ is a cross-sectional view taken at line 3′-3′ of FIG.3, and FIG. 3″ is a cross-sectional view taken at line 3″-3″ of FIG. 3.As shown in FIGS. 3′ and 3″, a plane 102 a is defined by the releasesurface 102. This plane 102 a is referred to herein in defining thedegree to which the respective non-adhesive materials are embedded intothe release liner 100. In this embodiment, the second pattern 110 is notembedded into the release liner 100, although in other embodiments itcould be fully or partially embedded (see below). As depicted in FIG.3′, a first portion of the second pattern is applied onto the releasesurface 102 of the release liner 100, and a second portion is appliedonto the upper surface of the embedded first pattern 106 where thepatterns overlap. In this embodiment, in which the upper or secondsurface 106 a of the embedded first pattern 106 is substantiallycoplanar with the plane 102 a defined by the release surface 102, thesecond pattern 110 forms a strip having a substantially straight, flatbottom or first surface 110 b. In FIGS. 3, 3′ and 3″ the first surfaces106 b of the pattern 106 embedded in the molding layer 104 define asecond plane 102 b which is illustrated in these figures assubstantially parallel to plane 102 a. Alternatively, the plane 102 bmay not be parallel to plane 102 a and/or the first surfaces 106 b mayform more than one plane which are different from plane 102 a.

In embodiments in which the embedded first pattern 106 extends below orabove the plane 102 a defined by the release surface 102 (not shown),the second pattern 110 may be formed having a stepped appearance (seeFIG. 8, which has such a stepped appearance). In other embodiments, theupper surface of the second pattern 110 may be substantially straightand flat as shown in FIGS. 3′ and 3″, forming a single plane parallel tothe plane 102 a, without sagging into or forming a stepped ridge overthe portion of the embedded first pattern 106 which is below the plane102 a.

FIG. 3″ is a cross-sectional view taken at line 3″-3″ of FIG. 3. Thefirst pattern 106 appears as a continuous structure, the upper or secondsurface 106 a of which is coplanar with the plane 102 a defined by therelease surface 102, and the first surfaces 106 b define a second plane102 b as described above. The three illustrated lines of the secondpattern 110 in FIG. 3 appear as three separate structures above theplane 102 a.

Following application of the second pattern 110, an adhesive layer 112is applied onto the release surface of release liner 100, thus formingan adhesive article 114 illustrated in FIG. 4. The adhesive layer 112includes a first surface 112 c (facing downward, not shown in FIG. 4), asecond surface 112 a and end edges 112 b. The first surface of theadhesive layer is adhered to the release surface 102 of the releaseliner 100 and to the exposed second surfaces of the two patterns. Thesecond surface 112 a is exposed on the upper surface of the adhesivearticle 114 shown in FIG. 4.

In one embodiment, shown in FIG. 5, a facestock 116 is applied to thesecond surface 112 a of the adhesive article 114 to form adhesivearticle 114 a. The facestock 116 may be any of the facestocks describedabove including paper or a polymeric film such as a vinyl (PVC) orpolyester film. The facestock 116 is selected for the desired propertiesneeded by the adhesive article 114 a. For instance, if the adhesivearticle 114 a is to be applied to a vehicle, then a vinyl facestock isgenerally selected for its flexibility and durability. A polyurethanefacestock may also be used for applications which are exposed toweathering. The facestock 116, although shown in FIG. 5 as a singlelayer, can comprise multiple layers with the layers selected forweatherability, printability, etc. The facestock 116 is in adhesivecontact with the adhesive layer 112, which may be, for example, apressure-sensitive adhesive. The adhesive 112 is in adhesive contactwith the release surface 102 and the exposed second surfaces of thenon-adhesive materials of the first pattern 106 and the second pattern110. As can be seen in FIG. 5, the second pattern 110 is embedded intothe adhesive layer. When the release liner 100 is removed from adhesivearticle 114 a, the non-adhesive material of the first pattern 106 andthe second pattern 110 remain adhered to the adhesive layer 112. It isunderstood that one or more of the non-adhesive materials may extendpartially into the adhesive layer but a portion, in one embodiment amajor portion, of at least one of the non-adhesive materials (pattern106) extends beyond or protrudes from the surface of the adhesive layer.

In another embodiment, shown in FIG. 6, the adhesive article 114 bincludes a second release liner 118, instead of the facestock 116 shownin FIG. 5, applied to the second surface 112 a of the adhesive layer112. The release liner 118 may be a release-treated paper or polymericfilm such as a vinyl (PVC) or polyester film. In other embodiments, therelease liner 118 may be the same as any of the materials disclosedherein for use as a release liner such as for the release liner 100. Inthe embodiment shown in FIG. 6, when both release liners 100 and 118 areremoved, a double-sided adhesive article is provided.

In one embodiment, the release liner 100 may have a texture formed onits release surface 102. The release liner is thereby a textured-finishrelease liner, as defined herein. The textured surface may be patterned,or the textured surface may have a matte finish. In one embodiment, thematte finish is a substantially random pattern. This texture may beimparted to the adhesive and non-adhesive materials using thetextured-finish release liner.

Other embodiments of adhesive articles and methods of the invention maybe obtained by adding, singly or in combination, additional layers ofnon-adhesive forms, adhesive, release coatings, release liners, andfacestocks. A few of the many examples of such adhesive articleconstructions are described herein.

The release liners used in the methods and adhesive articles of theinvention can have molding and release layers on both the first andsecond surfaces of a base or carrier layer allowing for the fabricationof transfer adhesives and double faced adhesive articles with theattributes of the invention on both of the adhesive surfaces.

A self wound transfer adhesive can be obtained from the adhesive articleof the invention illustrated above in FIG. 4 by (a) applying a releasecoating to the second surface of the release liner 100 or using a firstrelease liner 100 in which the second surface is a release surface, and(b) winding the adhesive article into a roll. The releasecharacteristics of the liner are such that the adhesive only adheres toone side of the liner when unwound.

A single liner double faced adhesive tape can be obtained from theadhesive article illustrated in FIG. 5 by (a) applying a release coatingto the second surface of the release liner 100 or using a first releaseliner 100 in which the second surface is a release surface, and (b)applying a second adhesive layer (not shown) having a first surface anda second surface onto the release surface wherein the first surface ofthe second adhesive layer is in contact with the release surface ofrelease liner 100. When this article is wound the exposed adhesiveadheres to the exposed surface of the facestock. The releasecharacteristics of the liner are such that one of the adhesives adheresto one side of the liner when unwound producing a face stock withadhesive on both sides and a liner adhered to one of the adhesivesurfaces.

FIG. 7 is a perspective view of the adhesive article 114 of the firstembodiment shown in FIG. 4, following removal of the release liner 100,with the article turned over so that the adhesive layer 112 is on thelower side of the article depicted in FIG. 7. As shown in FIG. 7, theadhesive article 114 c in this embodiment includes the second pattern110 embedded in the adhesive, and the first pattern 106 substantially onthe surface of the adhesive layer 112. Since the patterns 110 and 106,which were formed by application of the non-adhesive materials to therelease liner have been transferred to the adhesive layer 112, thepatterns are in reverse position in or on the adhesive layer 112relative to the position the patterns were placed in or on the releaseliner 100. As shown in FIG. 7, the adhesive article 114 c, followingremoval of the release liner 100, has a continuous layer of adhesive 112having a first surface 112 c and a back or second surface 112 a (notshown) and end edges 112 b; a first pattern 106 of first non-adhesivematerial forms having a first exposed surface 106 b and an opposedsurface 106 a in contact with the first surface 112 c of the adhesivelayer 112 and overlapping surface 110 b of the second pattern 110; and asecond pattern 110 of second non-adhesive material forms having apartially exposed second surface 110 b which is partially in contactwith the first surface 106 a of pattern 106 where the two patternsoverlap, and an opposed first 110 a surface embedded in the adhesivelayer 112. The first pattern 106 which was embedded in the releasesurface of the release liner now on the surface of the adhesive layer112. As shown, each of the first surfaces 106 b and 110 b of patterns106 and 110 of non-adhesive material forms is in a different plane, andthe first pattern 106 is in contact with the first surface 112 c of theadhesive layer 112 and protrudes from the adhesive layer 112. The planeformed the first surfaces 106 b corresponds to plane 102 b, and theplane formed by the first surfaces 110 b corresponds to plane 102 a asillustrated in and discussed in reference to FIGS. 3, 3′ and 3″. Thecombination of a non-adhesive pattern 110 in the adhesive and a secondnon-adhesive pattern protruding from the same side of the adhesive layerprovides air egress, repositionability and slideability.

A second embodiment of the method of the invention is illustrated inFIGS. 1, 8, 9, 9′, 9″, 9′″, 10 and 11. The method of the secondembodiment comprises (a) providing a release liner comprising a moldinglayer having a release surface and a second surface; (b) applying afirst pattern of a first non-adhesive material to a first portion of therelease surface; (c) applying a second pattern of a second non-adhesivematerial to a second portion of the release surface, wherein the secondpattern partially overlaps the first pattern; (d) embedding at least oneof the first and second non-adhesive materials into the molding layer;and (e) applying an adhesive layer having a first and second surface andend edges onto the release liner, wherein the front surface of theadhesive layer is adhered to the release surface of the release liner.In this embodiment, the first pattern initially is not embedded in themolding layer of the release liner. Rather the second pattern is appliedover the first pattern, portions or all of one or both patterns areembedded in the molding layer, and the part of the first patternoverlapped by the second pattern is embedded more deeply into therelease liner than the non-overlapped portions of the first pattern.

FIGS. 1, 8, 9, 9′, 9″, 9′″, 10 and 11 are perspective and crosssectional views depicting the second embodiment of making the adhesivearticle outlined above. FIG. 1 is a perspective view of the releaseliner 100 on pattern 106, as described above. The release liner 100includes the release surface 102, and the molding layer 104. The firstpattern 106 of a first non-adhesive material has been applied to therelease surface 102. In this second embodiment, the first pattern 106 isnot embedded into the release liner prior to application of a secondpattern 210. In the subsequent figures, for the sake of simplicity, themolding layer 104 is not shown as a separate layer; however, since it isto be understood that the release liner 100 includes the moldable layer104, either as a separate layer, or as the material of which the releaseliner 100 itself is formed, the entire layer is referred to by referencenumeral 104 to indicate that at least a part of the release liner 100 isa molding layer 104.

FIG. 8 is a perspective view of the release liner 100 (molding layer104), after applying the second pattern 210 of a second non-adhesivematerial over the first pattern. The second pattern 210 is applied in astepped pattern in this embodiment. In other embodiments (not shown),depending on the rheology and method of application of the non-adhesivematerial, the second pattern may be applied in a non-stepped form, thatis, with some bridging between the surface of the release liner 100 andthe profile of the first pattern 106. In yet other embodiments (notshown), again depending on the rheology and method of application of thenon-adhesive material, the second pattern may be applied so that itsteps over the first pattern 106, that is, does not bridge, and at thesame time results in the formation of the second pattern 210 having asubstantially planar upper surface between the areas of overlap, i.e.,without the gaps between the crossover points.

FIGS. 9, 9′, 9″ and 9′″ depict the release liner 100 after both thefirst pattern 106 and the second pattern 210 are embedded into therelease surface 102 and molding layer 104 of the release liner 100. FIG.9′ is a cross-sectional view taken at line 9′-9′ of FIG. 9, FIG. 9″ is across-sectional view taken at line 9″-9″ of FIG. 9, and FIG. 9′″ is across-sectional view taken at line 9′″-9′″ of FIG. 9. In this secondembodiment, both the first pattern 106 and the second pattern 210 areembedded into the molding layer 104 and the release surface 102. At thepoints of overlap, portions of the first pattern 106 are more deeplyembedded into the release surface 102, as shown in FIGS. 9′ and 9′″. Asshown in FIG. 9, the exposed upper or second surfaces of both patterns(106 a and 210 a, respectively) are substantially level or flush withthe release surface 102. In this embodiment, the first pattern 106 is attwo levels relative to the plane 102 a defined by the release surface102 of the release liner 100. A first portion 106′ remains substantiallyflush with the surface plane 102 a FIG. 9″, while a second portion 106″is more deeply embedded into the surface, and is actually below theoverlapping portion of the second pattern 210. In the embodiment shownin FIG. 9, the upper or second surface 210 a of the embedded portion ofthe first pattern 210 is substantially coplanar with the plane definedby the release surface 102, while the upper or second surface 106 a ofthe portion 106″ of the first pattern 106 which is overlapped by thesecond pattern 210 is below the lower or first surface 210 b of thesecond pattern 210. In other embodiments, either or both patterns may beincompletely embedded into the release surface 102 of the release liner.In such other embodiments, the upper surface of a portion of the firstpattern 106 is still below the lower surface of the overlapping portionof the second pattern 210. Thus, in this second embodiment, at least oneof the patterns of non-adhesive material is at least partiallyoverlapped by another pattern, and the overlapped portion is embeddedmore deeply into the molding layer 104 than other parts are embedded.

FIG. 9′ is a cross-sectional view of the release liner 100 taken at line9′-9′ of FIG. 9. As shown in FIG. 9′ (and in FIGS. 9″ and 9′″), a plane102 a is defined by the release surface 102. This plane 102 a isreferred to herein in defining the degree to which the respectivenon-adhesive materials are embedded into the release liner 100. Asdepicted in FIG. 9′, the second surface 210 a of the second pattern 210remains coplanar with the plane 102 a defined by the release surface 102of the release liner 100, and a portion 106″ of the first pattern 106 isembedded more deeply into the release surface 102.

Since both patterns 106 and 210 are embedded into the molding layer 104,the second surface 210 a of second pattern 210 is in the same plane 102a as the surface of the molding layer 104. The first surface 210 b is ina second plane identified in FIG. 9′ as plane 102 b. A portion of secondpattern 106 shown as 106″ is below pattern 210, and the lower or firstsurface of 106″ is in another plane identified as 102 c.

In other embodiments (not shown), the second pattern 210 may be embeddedto a depth whereby the upper or second surface 210 a of the secondpattern 210 is either above or below the plane 102 a. In these latterembodiments, the second pattern 210 either is only partially embedded,in which a portion of the second pattern 210 extends above the plane 102a, or is over-embedded, in which the surface 210 a of the second patternis below the plane 102 a. Similarly, in other embodiments, the firstpattern 106 may be over- or under-embedded. In such embodiments, theresulting surface of the release liner 100 may have 2 or more differentlevels, thus providing a wide range of possible combinations of initialtack, final tack, air egress, slideability and repositionability whenthe adhesive layer is subsequently applied. In any of these variations,the overlapped portion of the first pattern 106 is below the remainderof the first pattern 106.

As shown in FIG. 9″, which is a cross-sectional view taken at line 9″-9″of FIG. 9, in some areas of the release liner, the first pattern 106 isembedded to a level at which its second surface 106 a is exposed andsubstantially coplanar with the plane 102 a, and the surface is notoverlapped by the second pattern 210 in these areas.

FIG. 9′″ is a cross-sectional view taken at line 9′″-9′″ of FIG. 9. Inthis cross-sectional view, the second pattern 210 appears as a threeseparate pieces, corresponding to the strips shown in FIG. 9, and thefirst pattern 106 appears as a stepped structure (106′ and 106″). Inthis embodiment, in which the upper surface 210 a of the embedded secondpattern 210 is substantially coplanar with the plane 102 a, the firstpattern 106 forms a strip having a stepped appearance at the locationsof overlap by the second pattern, which is illustrated in FIG. 9′″.Thus, as shown by comparing FIGS. 9′ and 9″, and by viewing FIG. 9′″,the first pattern 106 is embedded to at least two different depths intothe layer 104. A portion 106″ of the second surface 106 a of pattern 106is in plane 102 a, and second surface 106 a of another portion 106″ isin plane 102 b. In addition, a portion of the first surface 106 b of106″ is in plane 102 b and another portion of the first surface of 106 bis in plane 102 c.

Following application of the second pattern 210 and embedding of boththe first pattern 106 and the second pattern 210, an adhesive layer 112is transferred onto the release surfaces 102 a, release liner 100, thusforming an adhesive article 214, as shown in FIG. 10. The adhesive layer112 includes a first surface 112 c (facing downward, not shown in FIG.10), a second surface 112 a and end edges 112 b. The first surface 112 cof the adhesive layer is adhered to the release surface 102 of therelease liner 100 and the second surfaces 106 a and 210 a of the twopatterns. The second surface 112 a is exposed on the upper surface ofthe adhesive article 214 shown in FIG. 10.

FIG. 11 is a perspective view of the adhesive article 214 of the secondembodiment shown in FIG. 10, following removal of the release liner 100,with the article turned over so that the adhesive layer 112 is on thelower side of the article depicted in FIG. 11. Since the patterns 210and 106, formed by application of the non-adhesive materials to therelease liner, in which the both patterns are embedded in the releaseliner 100, are transferred to the adhesive layer 112, the patterns arein reverse position on the adhesive layer 112 relative to the positionin the release liner 100. As shown in FIG. 11, the adhesive article 214a includes: adhesive layer 112; the second pattern 210 and the partiallyoverlapping first pattern 106 above the adhesive layer 112 and incontact with the first surface 112 c of the adhesive layer 112; andportions 106 c of the first pattern 106 extending above the firstsurface of pattern 210 at the overlap. As shown, each of the patterns106 and 210 of non-adhesive material forms has a first surface 106 b and210 b, respectively, and the first surface of the first pattern 106 isat two different heights (planes 102 b and 102 c) relative to firstsurface 112 c (plane 102 a), one of which is higher than the firstsurface 210 b of the second pattern 210 (plane 102 b). The differentheights provide protrusions of non-adhesive material which comprise airegress, repositionability and slideability. Stated in the alternative,the first surfaces 210 b of the second pattern 210 are in plane 102 b;the first surfaces 106 b of the first pattern 106 are in planes 102 band 102 c; and the planes of the first surfaces 106 b and 210 b aredifferent from the plane 102 a of the first adhesive surface 112 c.

In one embodiment, not shown with this second embodiment butsubstantially similar to the structure shown in FIG. 5 with respect tothe first embodiment, a facestock is applied to the second surface 112 aof the adhesive article 214. In one embodiment, not shown with thisembodiment but substantially similar to the structure shown in FIG. 6with respect to the first embodiment, an additional release liner isapplied to the back surface 112 a of the adhesive article 214.

FIGS. 1, 2, 12 a, 12 b, 13, 13′, 13″ and 14 are perspective and crosssectional views depicting a third embodiment of making an adhesivearticles of the invention. FIGS. 1 and 2 are perspective views of arelease liner 100 or a first pattern of non-adhesive material from 106,as described above. In this third embodiment, the first pattern 106 isembedded into the release liner 100 prior to subsequent steps, as shownin FIGS. 2 and 2′. However subsequent steps differ in this embodiment,thus the adhesive article is identified by the reference numeral 314, inaccordance with the differences between this embodiment and the firstand second embodiments.

In this third embodiment, rather than applying a second pattern over theembedded first pattern 106, as in the first embodiment, the embeddedfirst pattern 106 is removed prior to application of a second pattern310. The sequential steps of embedding the first pattern 106, followedby removal of the first pattern 106, shown in FIGS. 12 a and 12 b,results in the formation of a negative or void, or channeling pattern122 in the release liner 100, as shown in FIGS. 12 b and 13. As inprevious FIGS. 8-10, molding layer 104 is used to represent the releaseliner 100.

FIGS. 12 a and 12 b are cross-sectional views of the release liner 100similar to FIG. 2′, except that in FIG. 12 a, an adhesive layer 120 hasbeen applied to the release surface 102. The adhesive used in theadhesive layer 120 is selected to provide stronger adhesion to thenon-adhesive material forming the first pattern 106 than the adhesion ofthe non-adhesive material has to the release surface 102 of moldinglayer 104. As shown in FIG. 12 b, when the adhesive layer 120 isremoved, the non-adhesive material forming the first pattern 106 isremoved with the adhesive layer 120, thus forming the voids or channels122 in the molding layer 104.

In an alternative embodiment to using the sequential steps of applying afirst pattern of non-conductive material forms to the surface of moldinglayer, embedding the first pattern, and removing the first pattern toform voids or channels as shown in FIG. 12 a, 12 b and 13, the moldinglayer 300 of FIG. 13 may be prepared by directly embossing the firstpattern into the surface 102 of molding layer 104. Any of the embossingprocedures known in the art may be utilized to provide the desired firstpattern. For example, the first pattern may be obtained by applying heatand pressure to the surface of a molding layer using a roller or platenhaving the desired pattern in or on its surface.

In other embodiments, the non-adhesive material may be removed by othermeans, depending on the material of which the non-adhesive material isformed. For example, the non-adhesive material may be removed bydissolution with an appropriate solvent, or by an electrolytic method,or by a physical method. In most cases, the use of adhesive as describedabove is suitable.

FIG. 13 is a perspective view of molding layer 104, following theremoval of the first pattern of non-adhesive material forms 106. Asshown in FIG. 13, removal of the first pattern 106 leaves voids orchannels 122 remaining in the surface of the molding layer 104 in apattern substantially corresponding to the first pattern 106. As will beunderstood, in this embodiment, in which the first pattern 106constitutes lines, when the non-adhesive material of the first pattern106 is removed, the void or channel pattern 122 is substantially in theform of similar lines. In other embodiments, for example where the firstpattern 106 includes a line of dots, “dashes” or elongated formsseparated by regions free of the non-adhesive material, a correspondingsimilar pattern will be formed when the non-adhesive material isremoved.

Referring now to FIGS. 14, 14′ and 14″, a second non-adhesive materialis applied to the molding layer 104 to form a second pattern 310 havinga second surface 310 a and a first surface 310 b. The second pattern 310is applied in a stepped pattern in this embodiment. In other embodiments(not shown), depending on the rheology and method of application of thenon-adhesive material, the second pattern may be applied in anon-stepped form, that is, with some bridging between the surface of themolding layer 104 and the profile of the channel 122. In yet otherembodiments (not shown), again depending on the rheology and method ofapplication of the non-adhesive material, the second pattern 310 may beapplied so that it steps into the channel 122, that is, does not bridge,and at the same time results in the formation of the second pattern 310having a substantially planar upper surface, i.e., without the gapsbetween the crossover points.

FIG. 14′ is a cross-sectional view taken at line 14′-14′ of FIG. 14 andFIG. 14″ is a cross-sectional view taken at line 14″-14″ of FIG. 14. Inthis third embodiment, some portions 310 d of the second pattern 310 areembedded in the channels 122 in molding layer 104, and some portions 310c are on the original release surface 102, as shown in FIG. 14. It isnoted that the portions 310 d have not actually been directly embeddedas in the first two embodiments. The embedded portions 310 d of thesecond pattern 310 are considered to be embedded because when they areapplied into the void or channel 122 left by removal of the firstpattern 106, and the portions 310 d are effectively in an embeddedposition relative to the plane 102 a of the release surface 102 ofmolding layer 104. Thus, in this embodiment, the second pattern 310comprises elements 310 c and 310 d at two levels relative to the plane102 a. A first portion 310 c remains above the plane 102 a, i.e., notembedded, while a second portion 310 d is embedded into the surfacebelow the plane 102 a. In the embodiment shown in FIG. 14′, the upper orsecond surface of the embedded portion 310 d of the second pattern 310is substantially coplanar with the plane 102 a defined by the releasesurface 102. In other embodiments, the second 310 d portion may beincompletely embedded into the release surface 102 of the release liner,such that the upper surface of the portion 310 d is above the level ofthe plane 102 a. In another embodiment, in which the first pattern 106is over-embedded prior to its removal, the upper surface of the portion310 d may be below the plane 102 a. In this embodiment, the portion 310d is substantially at or above the level defined by the plane 102 a,since it is applied directly onto the original release surface 102.

As shown in FIG. 14″, which is a cross-sectional view taken at line14″-14″ of FIG. 14, in some areas of the release liner, the secondpattern 310 is embedded, or fills the channel 122 such that the uppersurface of the portion 310 c is substantially coplanar with the plane102 a, as a result of its being deposited on the bottom of the channel122. In other embodiments, the second pattern 310 may be applied using anon-adhesive material having a suitable rheology which allows thenon-adhesive material to fill the channel 122 while at the same timefilling the gaps between the portions 310 c formed by the step-likeapplication of the pattern 310.

Following application of the second pattern 310, as shown in FIG. 14, anadhesive layer 112 is applied over the molding layer 104 and secondpattern 310, thus forming an adhesive article 314, as shown in FIG. 15.The adhesive layer 112 includes a first surface 112 c (facing downward,not shown in FIG. 15), a second surface 112 a and end edges 112 b. Thefirst surface 112 c of the adhesive layer is adhered to the releasesurface 102 of the release liner 100 and the exposed surface of thesecond pattern. The second surface 112 a is exposed on the upper surfaceof the adhesive article 314 shown in FIG. 15.

The adhesive structure 314 shown in FIG. 15 (and with additionalreference to FIGS. 14, 14′ and 14″) includes a release liner 100 havinga molding layer 104; a continuous layer of adhesive 112 having a frontsurface 112 c (not shown), a back surface 112 a and end edges 112 b, inwhich the front surface 112 a of the adhesive 112 is adhered to therelease surface 102 of molding layer 104, the first embossed pattern 122and the second pattern 310. A portion 310 d of the second pattern 310 isat least partially embedded in portions of the first embossed pattern122.

FIG. 16 is a perspective view of the adhesive article 314 a of the thirdembodiment shown in FIG. 15, following removal of the release liner 100,with the article turned over so that the adhesive layer 112 is on thelower side of the article depicted in FIG. 16. As shown in FIG. 16, theadhesive article 314 a includes the second pattern 310 fully embedded inthe adhesive, and the pattern of channels 122 formed by the firstpattern 106 revealed as ridges 122 a extending above the first surface112 c of the adhesive layer 112. The ridges 122 a include in some areasthe adhesive of the adhesive layer 112 and in some areas portions 310 cof the second pattern 310, as shown in FIG. 16. The patterns 310 andchannels 122, formed by application of the non-adhesive materials to therelease liner (including removal of the first pattern 106 to form thechannels 122), in which the both the pattern 310 and the channels 122are at least partially embedded in the release liner 100, form anegative of the structure eventually formed in the adhesive layer 112.When the structure is transferred to the adhesive layer 112, thepatterns are in reverse position in or on the adhesive layer 112relative to the position in or on the release liner 100. As shown inFIG. 16, the adhesive article 314 a, following removal of the releaseliner 100, has a continuous layer of adhesive 112 having a first surface112 c, a second surface 112 a (not shown) and end edges 112 b; a firstpattern formed by the ridges 122 a, a second pattern 310 of non-adhesivematerial forms, a portion of the pattern 310, which was more deeplyembedded in the release surface of the release liner, now displayed inthe ridges 122 a of the adhesive layer 112, while the remaining portionsof the non-adhesive material of the pattern are embedded in the surface112 c of the adhesive layer 112. That is, the top or first surface 310 bof a portion of second pattern 310 is in the same plane as first surface112 c of the adhesive layer, and the first surface 310 b another portionof second pattern 310 is in a plane that is different from the planeformed in the other portion of the second pattern. The first surface ofthe second pattern in the different planes provides air egress,repositionability and slideability.

In the embodiment shown in FIGS. 14, 15 and 16, the second pattern 310has been applied at an angle of about 90° to the direction of the firstpattern 106 and of the channel structure 122. As noted earlier, thesecond pattern may be applied at an angle of about 30°, about 45°, about60°, about 75° or any other selected angle relative to the direction ofthe first pattern 106 and the channel structure 122.

In one embodiment, the adhesive articles of the invention, such asadhesive article 314 a illustrated in FIG. 16 may be described ascomprising a continuous layer of adhesive having a first surface and asecond surface, and a first embossed pattern in the first surface of theadhesive layer, and a second pattern of non-adhesive material forms,wherein the second pattern at least partially overlaps the first patternand is embedded in the first surface of the adhesive layer; each of saidembossed pattern and second pattern has an exposed first surface whereinthe first surface of at least a portion of the first embossed pattern isin a plane that is different from the plane of the first surface of atleast a portion of the second pattern of non-adhesive forms.

In one embodiment, not shown with this third embodiment butsubstantially similar to the structure shown in FIG. 5 with respect tothe first embodiment, a facestock is applied to the back surface 112 aof the adhesive article 314 a. In another embodiment, not shown, anadditional release liner is applied to the back surface 112 a of theadhesive article 314 a.

The temperatures used to embed the non-adhesive material form into themolding layer in accordance to the methods of the invention depend onthe materials used, but typically are in the range of about 150° toabout 300° F. (about 65° C. to about 150° C.), or from about 200° toabout 250° F. (about 93° C. to about 121° C.) for embedding into therelease liner. The embedding pressure is also material dependent and maybe between about 25 to about 150 pounds per square inch (psi)(about 1.7Kg/cm² to about 11 Kg/cm²), or from about 50 to about 100 psi (about 3.5Kg/cm² to about 7 Kg/cm²).

FIG. 17 illustrates one embodiment of the embedding process. Theembedding process uses a release liner with a moldable layer under therelease surface, as described herein. In one embodiment, the moldinglayer is composed of polyolefins, such as low, medium and high densitypolyethylene, propylene or mixtures thereof. In one embodiment, themolding layer has a thickness of 10 μm to about 50 μm. In otherembodiments, the thickness may be from about 20 μm to about 70 μm orfrom about 30 μm to about 60 μm.

Referring to FIG. 17, a release liner 100 is printed on the releasesurface 102 with non-adhesive material in a first pattern 106. Therelease liner 100 is passed through laminating rollers 124 a and 124 b.In one embodiment, the release liner and bottom laminating roller areheated, and the upper laminating roller is cooled. Other configurationsmay be used. The materials selected determine the heating and coolingconfigurations that may be used. The laminating rollers may be steelrollers, rubber rollers or a combination.

In another embodiment illustrated in FIG. 18, the upper roller 124 a mayinclude a textured surface. The textured surface may be used forapplying the differential height pattern in the embedding steps of themethod of the present invention or the textured surface may be used toapply the embossed patterns described herein. FIG. 18 schematicallyillustrates two possible embodiments of textured surfaces for use, e.g.,on a laminating roller. In FIG. 18, the roller 124 a includes a surfacehaving either a first texture 126 or a second texture 128. As indicatedin FIG. 18, the scale of the texturing may be quite small, and the scaleis magnified for exemplification. In the first texture 126, the roller124 a has a substantially square-toothed appearance. In the secondtexture 128, the roller 124 a has a two-level toothed appearance. Itshould be recognized that these textures are exemplary only, and manyother textures may be used.

While the invention has been explained in relation to its preferredembodiments, it is to be understood that various modifications thereofwill become apparent to those skilled in the art upon reading thespecification. The features of the various embodiments of the adhesivearticles described herein may be combined into within an adhesivearticle. The various methods of manufacturing the adhesive articles ofthe present invention described herein may also be combined. Therefore,it is to be understood that the invention disclosed herein is intendedto cover such modifications as fall within the scope of the appendedclaims.

1. An adhesive article comprising: a continuous layer of adhesive having a first surface, a second surface and end edges, and a first pattern of first non-adhesive material forms and a second pattern of second non-adhesive material forms wherein the second pattern partially overlaps the first pattern; at least one of said first and second patterns is at least partially embedded in the first surface of the adhesive layer; each of said first and second patterns has an exposed first surface and an opposite second surface that is in contact with the adhesive; the first surface of at least a portion of the first pattern of non-adhesive forms is in a plane that is different from the plane of the first surface of at least a portion of the second pattern of non-adhesive forms; and at least a portion of the first pattern protrudes from the first surface of the adhesive layer.
 2. The adhesive article of claim 1 further comprising a facestock adhered to the second surface of the adhesive layer.
 3. The adhesive article of claim 1 further comprising a release liner adhered to the second surface of the adhesive layer.
 4. An adhesive article comprising: a release liner comprising a release surface, a molding layer and a second surface; a continuous layer of adhesive having a first surface, a second surface and end edges, wherein the first surface of the adhesive is adhered to the release surface of the release liner; a first pattern of first non-adhesive material forms having a first surface and a second surface; and a second pattern of second non-adhesive material forms having a first surface and a second surface, wherein the second pattern partially overlaps the first pattern; at least one of the first and second patterns is at least partially embedded in the release surface and molding layer of the release liner; the first surface of each of the two patterns is in contact with the release surface of the release liner, the second surface of each of the two patterns is in contact with the adhesive layer; and the first surface of at least a portion of the first pattern of non-adhesive material forms is in a plane that is different from the plane of the first surface of at least a portion of the second pattern of non-adhesive material forms.
 5. The adhesive article of claim 4 wherein each of the non-adhesive material forms independently has an average thickness of about 30 nanometers to about 100 μm.
 6. The adhesive article of claim 4 wherein each of the non-adhesive material forms independently has an average thickness of about 3 μm to about 30 μm.
 7. The adhesive article of claim 4 wherein each pattern of non-adhesive material forms independently is applied by printing, vacuum metallization or sputtering.
 8. The adhesive article of claim 4 wherein at least one of the non-adhesive materials independently comprises at least one printing ink, UV curable ink or coalescing ink.
 9. The adhesive article of claim 4 wherein each pattern of non-adhesive material forms independently comprises a plurality of dots, lines or combinations thereof.
 10. The adhesive article of claim 4 wherein each pattern of non-adhesive material forms independently comprises a plurality of lines having an average width of from about 12 μm to about 250 μm and an average thickness of from about 30 nanometers to about 100 μm.
 11. The adhesive article of claim 4 wherein the each pattern of non-adhesive material forms independently comprises a plurality of lines, and wherein at least 50% of the lines intersect the end edges of the adhesive layer.
 12. The adhesive article of claim 4 wherein each pattern of non-adhesive material forms comprises a plurality of non-intersecting lines, and wherein the lines from the first pattern and the lines from the second pattern intersect to form a grid pattern.
 13. The adhesive article of claim 4 wherein the adhesive layer comprises a pressure sensitive adhesive or a heat-activated adhesive.
 14. The adhesive article of claim 4 wherein at least one of the first and second non-adhesive material comprises a porous non-adhesive material.
 15. The adhesive article of claim 14 wherein the porous non-adhesive material comprises an elastomer.
 16. The adhesive article of claim 4 wherein the adhesive is a pressure sensitive adhesive.
 17. The adhesive article of claim 4 wherein the release surface of the release liner has a textured or matte surface.
 18. The adhesive article of claim 17 wherein the first surface of the adhesive layer has a textured surface that is complementary to the textured surface of the release liner.
 19. The adhesive article of claim 4 wherein the release surface of the release liner has a Sheffield roughness of at least about
 50. 20. The adhesive article of claim 4 further comprising a facestock adhered to the second surface of the adhesive layer.
 21. The adhesive article of claim 4 further comprising a second release liner adhered to the second surface of the adhesive layer.
 22. The adhesive article of claim 4 wherein the second surface of the release liner has a release coating thereon.
 23. The adhesive article of claim 22 further comprising a facestock having a first and second surface wherein the first surface is in contact with the second surface of the adhesive layer and a second adhesive layer having a first and second surface wherein the first surface of the second adhesive layer is in contact with the second surface of the facestock.
 24. The adhesive article of claim 23 further comprising a second release liner adhered to the second surface of the second adhesive layer. 